Corrugating rollers

Abstract

Corrugating rollers include an outer surface, a first flute on the outer surface, the first flute having a first height, and a second flute on the outer surface, the second flute having a second height that is different than the first height.

The invention claimed is: 
     
       1. A corrugating roller configured to, in operation, corrugate paper materials for use in forming shiping containers, comprising:
 an outer surface; 
 a first end and a second end opposite to the first end; 
 at least three first groups of flutes at and along at least three first areas of the outer surface, each respective first group of flutes of the at least three first groups of flutes having a first height, each respective first group of flutes of the at least three first group of flutes are configured to, in operation, corrugate paper materials, and each respective first group of flutes of the at least three first groups of flutes extend continuously along the outer surface from the first end to the second end; and 
 at least three second groups of flutes at and along at least three second areas of the outer surface, each respective second group of flutes of the at least three second groups of flutes having a second height that is less than the first height, each respective second group of flutes of the at least three second groups of flutes are configured to, in operation, corrugate paper materials, and each respective second group of flutes of the at least three second groups of flutes extend continuously along the outer surface from the first end to the second end; 
 wherein each respective first area of the at least three first areas are larger than each respective second area of the at least three second areas, each respective first area of the at least three first areas are fully and completely separated from each other by each respective second area of the at least three second areas, and each respective second area of the at least three second areas are fully and completely separated from each other by each respcetive first area of the at least three first areas. 
 
     
     
       2. The corrugating roller of  claim 1 , wherein respective flutes of the at least three first groups of flutes are parallel with respective flutes of the at least three second groups of flutes. 
     
     
       3. A corrugating machine configured to corrugate paper materials for use in forming shipping containers, comprising:
 a first corrugating roller and a second corrugating roller each having an outer surface, the first corrugating roller and the second corrugating roller are configured to, in operation, corruagte paper materials, wherein the first corrugating and the second corrugating roller both include:
 an outer surface; 
 a first end and a second end opposite to the first end; 
 at least three first group of flutes at and along at leaset three first areas of the outer surface, the at least three first groups of flutes having a first height, the at laest three first groups of flutes are configured to, in operation, corrugate paper materials, the at least three first groups of flutes extend continuously along the outer surface from the first end to the second end; and 
 at least three second groups of flutes at and along at least three second areas of the outer surface, the at least three second groups of flutes having a second height that is less than the first height, the at least three second groups of flutes are configured to, in operation, corrugate paper materials, the second group of flutes extend continuously along the outer surface from the first end to the second end; 
 wherein each respective first area of the at least three first areas is larger than each repective second area of the at least three second areas, each respective first area of the at least three first areas are fully and completely separated from each other by each respective second area of the at least three second areas, and each repective second area of the at least three second areas are fully and completely separate from each other by each respective first area of the at least three first areas. 
 
 
     
     
       4. The corrguating machine of  claim 3 , wherein at least one of the first corrugating roller and the second corrugating roller is heated. 
     
     
       5. The corrguating machine of  claim 3 , wherein the first corrugating roller and the second corrugating roller are solid. 
     
     
       6. The corrguating machine of  claim 3 , wherein the first corrugating roller and the second corrugating roller are made of steel. 
     
     
       7. The corrugating machine of  claim 3 , wherein the first height is 0.125 inches. 
     
     
       8. The corrugating machine of  claim 3 , wherein the first height is between 0.125 inches and 0.16 inches. 
     
     
       9. The corrugating machine of  claim 3 , wherein a width between adjacent peaks of respective flutes of the at least three first groups of flutes is 0.125 inches. 
     
     
       10. The corrugating machine of  claim 3 , wherein a width between adjacent peaks of respective flutes of the at least three first groups of flutes is between 0.125 inches and 0.16 inches. 
     
     
       11. The corrugating machine of  claim 3 , wherein respective flutes of the at least three first groups of flutes consists of B-sized flutes and respective flutes of the at least three second groups of flutes consists of N-sized flutes. 
     
     
       12. The corrugating machine of  claim 3 , wherein respective flutes of the at least three first groups of flutes consists of B-sized flutes and respective flutes of the at lesat three second groups of flutes consists of F-sized flutes. 
     
     
       13. The corrugating machine of  claim 3 , wherein respective flutes of the at least three first groups of flutes are parallel with respective flutes of the at least three second groups of flutes.